Investing in a walk-in cooler unit is a significant decision, often one of the most crucial for your business. One of the key components to consider is the flooring. Given the high volume of traffic these surfaces endure, selecting the appropriate flooring material is essential to prevent damage and ensure durability. The right type of flooring enhances the efficiency of your walk-in and extends its lifespan, making it a vital factor in your overall investment.
Walk-in coolers and freezers come in various shapes, sizes, and configurations, each tailored to specific applications. The type of flooring you choose should align with the intended use of your cooler. Here are some essential flooring options to consider:
No Floor
Not having a floor is an option for walk-in coolers and freezers, offering easy access without ramps. This design allows heavy equipment, such as carts and pallet jacks, to load and unload products efficiently, as it’s installed directly over the existing floor.
Considerations for Coolers and Freezers
Coolers: When using this option for coolers, an existing concrete pad effectively maintains the interior temperature, typically designed to be around 35°F.
Freezers: For freezers, the concrete slab must include a proper layer of foam insulation and a thermal barrier around the perimeter. This setup helps prevent condensation issues on the concrete pad and surrounding walls.
Wall and Floor Integration
In most installations, walls connect to the floor using either PVC screeding or a metal track:
PVC Screeding: This NSF-approved channel cradles the wall panels, providing a seamless wall-floor joint.Metal Track: This option must be finished inside with a cove base molding and locks into place with the walls, offering enhanced stability—especially in seismic zones.
Aluminum Paneling Floors
Aluminum paneling floors are a popular choice for walk-ins, offering durability and strength. These panels are constructed similarly to the walls of most walk-ins, featuring a robust interior material designed for light traffic.
Think of them as a sandwich: two metal sheets serve as the outer layers, while insulation fills the core. These panels can typically support around 600 pounds per square foot of stationary load, making them suitable for foot traffic and stationary racks with lightboxes. However, they may not be sufficient for heavier loads.
Wood Underlayment
Incorporating wood underlayment beneath the aluminum interior layer enhances weight distribution, making this flooring option ideal for heavier loads. While more expensive to install and replace, wood underlayment is essential for applications requiring significant support.
This paneling can typically handle stationary loads of approximately 1,000 to 1,500 pounds per square foot, providing ample strength for medium to large carts filled with kegs or other heavy items.
Reinforced Flooring
Reinforced flooring is the premier choice for walk-in coolers, designed to handle the heaviest loads with ease. The reinforcement is achieved through fiberglass-reinforced plastic (FRP) channels embedded within the insulation.
These floors can support nearly 2,600 pounds per square foot, making them essential for walk-ins intended to accommodate full hand-jack pallets. For example, a pallet loaded with soda can easily exceed 2,000 pounds, highlighting the need for robust flooring in high-capacity applications.
Walk-In Floor Repair & Replacement
Knowing when to repair or replace your walk-in cooler floors is crucial for maintaining efficiency and safety. Several signs and indicators can help you determine if it’s time for action.
Floor Damage
Floor damage is the most apparent sign that your walk-in requires attention. The area directly in front of the door typically shows wear first, as it experiences the highest traffic. Depending on your flooring type, look for gouges, grooves, or deep scuff marks.
Inspect other areas of the unit for holes and gouges caused by shelving or heavy items. Additionally, watch for large dents, which can result from employees accidentally dropping heavy objects or rolling excessive weight onto the floor.
Delamination or warping of the interior metal surface may also occur if the floors are subjected to loads beyond their design specifications. Addressing these issues promptly can help prevent further damage and maintain the integrity of your walk-in.
Temperature
Monitoring temperature is crucial for the efficiency of your walk-in unit. If you notice that your cooler or freezer is using more energy than before to maintain a safe temperature, it may be a sign of underlying issues.
While factors like the number of door openings per hour can complicate this assessment, consistent temperature fluctuations can provide valuable insights into the health of your floor and other components. Addressing these changes promptly can help prevent more significant problems down the line.
Frost and Condensation
The presence of frost or condensation in your walk-in is a concerning indicator that something may be amiss. The evaporator unit should effectively remove moisture from the air; if it’s not functioning properly, you may notice excessive frost buildup on boxes, goods, and surfaces.
While some frost and condensation can be normal due to regular operation, significant accumulations may signal an underlying issue with the refrigeration system. Monitoring these conditions closely can help you address potential problems before they escalate.
How to Fix Floors?
Now that you know how to identify signs of damage, you might wonder how to fix a walk-in floor. For minor issues, such as small gaps, sealing and patching can be effective solutions. However, for larger problems—like floor bowing, significant gaps, large punctures, or excessive condensation—it’s essential to consult a refrigeration technician.
Repairs can range from simple overlays to complete floor replacements, and delaying these fixes can lead to more complex and costly issues down the line. Addressing problems promptly ensures your walk-in remains efficient and safe.For a more detailed overview of Arctic floor types and features, be sure to check out our brochure on floor types.